Thermal-fluid behavior and distribution of ceramic particles during laser melting deposition of TiC/TC4 composite materials
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摘要:
颗粒增强钛基复合材料在航空航天等领域具有广阔的应用前景，采用仿真与试验相结合的方法，对激光熔化沉积TiC/TC4复合材料过程中的热-流行为和沉积层中陶瓷颗粒的分布状态进行了研究. 结果表明，工艺参数对熔池的热-流行为及沉积层形貌具有显著的影响，熔池表面的流体流动呈波纹状，熔融金属从熔池中心向四周流动；熔池底部等温面上熔融金属从四周流向熔池底部，并出现漩涡现象. 在激光熔化沉积过程中，TiC颗粒穿透熔池表面的Marangoni对流区，在熔池中与流体交互作用，最终在沉积层中出现沉积层中上方部位团聚、沉积层中下方部位团聚、沉积层中均匀分布等分布状态.
Abstract:Particulate reinforced titanium matrix composites have broad application prospects in aerospace and other fields. The thermal-fluid behavior and the distribution of the ceramic particles in the deposited layer during the laser melting deposition of TiC/TC4 composites were studied by combining simulation and experiment. The results show that the process parameters have a significant effect on the thermal-fluid behavior of the molten pool and the morphology of the deposited layer. With the increase of laser power, the molten pool size and the maximum fluid flow rate increase. As the scanning speed increases, the molten pool size and the maximum fluid flow rate decrease. The fluid flow on the surface of the molten pool is corrugated. The molten metal flows from the center of the molten pool to the periphery. The molten metal on the isothermal surface of the bottom of the molten pool flows from the periphery to the bottom, and the vortex flow phenomenon occurs. In the process of laser melting deposition, TiC particles penetrate the Marangoni convection zone on the surface of the molten pool and interact with the fluid in the molten pool. Finally, they may appear in the distribution of the agglomeration in middle-upper part, the agglomeration in middle-lower part and uniform distribution in the deposited layer.
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图 1 TiC/TC4复合材料激光熔化沉积模型
Figure 1. Laser melting deposition model of TiC/TC4 composite materials. (a) geometric model structure; (b) geometric model meshing; (c) partial meshing
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图 2 激光熔化沉积过程熔池形成及长大过程
Figure 2. Formation and growth of molten pool in laser melting deposition process. (a) t = 40 ms; (b) t = 80 ms; (c) t = 120 ms; (d) t = 160 ms; (e) t = 200 ms; (f) t = 240 ms; (g) t = 280 ms; (h) t = 320 ms; (i) t = 360 ms
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图 3 不同激光功率下激光熔化沉积过程中熔池形貌及表面流场
Figure 3. Morphology and surface flow field of molten pool during laser melting deposition at different laser powers. (a) P = 1 200 W, vs = 10 mm/s; (b) P = 1 400 W, vs = 10 mm/s; (c) P = 1 600 W, vs = 10 mm/s; (d) P = 1 400 W, vs = 8 mm/s; (e) P = 1 400 W, vs = 12 mm/s
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图 4 激光熔化沉积试验设备示意图
Figure 4. Schematic diagram of laser melting deposition test equipment.
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图 5 不同工艺参数下熔覆层横截面形貌
Figure 5. Cross-section morphology of cladding layer under different process parameters. (a) P = 1 400 W, vs = 8 mm/s; (b) P = 1 400 W, vs = 10 mm/s; (c) P = 1 400 W, vs = 12 mm/s; (d) P = 1 200 W, vs = 10 mm/s; (e) P = 1 600 W, vs = 10 mm/s
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图 6 不同工艺参数下沉积层横截面尺寸
Figure 6. Cross-section dimensions of the deposited layer under different process parameters. (a) schematic diagram of cross-section dimension measurement; (b) variation of cross-section dimension with laser power; (c) variation of cross-section dimension with scanning speed
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图 7 不同工艺参数下沉积层中TiC颗粒的分布状态
Figure 7. Distribution of TiC particles in the deposited layer under different process parameters. (a) P = 1 400 W, vs = 8 mm/s; (b) P = 1 400 W, vs = 10 mm/s; (c) P = 1 400 W, vs = 12 mm/s; (d) P = 1 200 W, vs = 10 mm/s; (e) P = 1 600 W, vs = 10 mm/s
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图 8 熔池中粒子迁移机制
Figure 8. Mechanism of particle migration in molten pool. (a) particles enter the gas/liquid interface; (b) particle migration mechanism near the back end of the molten pool; (c) particle migration mechanism near the front end of the molten pool; (d) migration mechanism of cross-section of the molten pool
表 1 TiC/TC4复合材料激光熔化沉积试验工艺参数
Table 1 Design table of technological parameters for laser melting deposition test of TiC/TC4 composite materials
编号 激光功率
P/W扫描速度
vs /(mm·s−1)TiC 含量
w(%)送粉率
vf /(g·min−1)1 1400 8 20 9.6 2 1400 10 20 9.6 3 1400 12 20 9.6 4 1200 10 20 9.6 5 1600 10 20 9.6 
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